Printable and foldable sheet mailer construction for inserts and method of forming same

ABSTRACT

An 8½ by 11 inch paper sheet construction having a pattern of score and perforated lines formed thereon is provided to the user. The lines form corner tear-away strips, a central panel, left and right side flaps, and top and bottom flaps. The user enters into his computer the desired indicia to be printed on inside surfaces of one or more of the central panel and top and bottom flaps and the desired address indicia to be printed on the outside surface of the central panel, and then has the desired indicia and address indicia printed on the sheet construction by feeding it into his desk top printer. He then tears off the four corner tear-away strips. He next places the desired flat object(s) (such as postcards) he wants to mail on the inside surface of the central panel and folds the two side flaps in, the bottom flap up and the top flap down. A seal is then applied to releasably secure the top flap to the bottom flap. Postage is applied to the outside of the addressed central panel and the mailer with flat object(s) is mailed.

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of U.S. Provisional Application No. 60/248,348 filed Nov. 14, 2000, whose contents are hereby incorporated by reference in its entirety.

BACKGROUND OF THE INVENTION

[0002] Many businesses and individuals desire to mail to their customers, potential customers, colleagues, friends or others flat objects such as postcards, photographs, CDs and the like. Often they want to send them in a mass mailing to numerous addresses. They are typically sent in pre-printed mailers. The users often desire to have advertisements or other messages printed on the mailers to reduce the postage and mailing costs associated with a separate message sheet inserted in the mailer. These are typically custom advertisements or messages, and may be the same for all addresses or different ones for all addresses.

SUMMARY OF THE INVENTION

[0003] Thus, a suitable mailer system where the user can compose the custom message on his personal computer and input the addresses and have the messages and addresses printed on 8½ by eleven inch sheets using his desk top (ink jet) printer is desired. One desirable mailer size would hold standard sized postcards, such as four by six inch postcards.

[0004] Directed to remedying the problems in the prior art, a paper sheet construction having a pattern of score and perforated lines formed thereon is provided to the user. The lines form corner tear-away strips, a central panel, left and right side flaps extending out from sides of the central panel, and top and bottom flaps extending out from top and bottom edges, respectively, of the central panel. The user has the option to type into his computer the desired indicia to be printed on inside surfaces of one or more of the central panel and top and bottom flaps and the desired address indicia to be printed on the outside surface of the central panel. He then has the desired indicia and address indicia printed on the paper sheet construction by feeding (once for printing single side of the sheet, twice for printing on both sides of the sheet or once where the printer is a duplexing printer) into his desk top (ink jet) printer. The paper sheet construction preferably is a standard size sheet (e.g., 8½ by eleven inches) for easy feeding into today's typical printer. The user then tears the four corner tear-away strips off of the printed sheet to form a mailer sheet.

[0005] He next places the flat object(s) (such as postcards, photographs or business cards) he wants to mail on an inside surface of the central panel of the mailer sheets and folds the two side flaps in, the bottom flap up and the top flap down. A sticker or mailing seal (or the like) is then applied to releasably secure the top flap to the bottom flap. Postage if not already on the mailer sheet is applied to the outside of the addressed central panel and the mailer is then mailed. The recipient simply breaks the seal, unfolds the mailer sheet and removes the flat object.

[0006] Another definition of the invention is a mailer sheet (preferably of a standard size) adapted to be fed into and printed on by printers (such as today's desk top ink jet printers) and having a pattern of weakened fold and tear lines on one or both surfaces thereof. The user custom prints on his printer the addresses and messages on the sheet. The sheet is then torn and folded up with one or more substantially flat objects therein, sealed and mailed to the intended recipient.

[0007] A further definition is the method of forming the mailer construction, ready for mailing.

[0008] Other objects and advantages of the present invention will become more apparent to those persons having ordinary skill in the art to which the present invention pertains from the foregoing description taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009]FIG. 1 is a top plan view of a mailer sheet construction of the present invention;

[0010]FIG. 2 is perspective view showing a stack of the mailer sheets of FIG. 1 in an infeed tray of a printer (or copier) and a stack of the mailer sheet constructions in a printed condition after having passed through the printer in an outfeed tray thereof;

[0011]FIG. 3 is a bottom perspective view of one of the printed mailer sheets of FIG. 2, illustrating the four corner tear-away strips having been torn away to form a printed mailer sheet and two postcards (or other flat object(s)) ready for placement in the printed mailer sheet;

[0012]FIG. 4 is a top perspective view of the printed mailer sheet of FIG. 3 with the postcards positioned in the pocket thereof, and the flaps being folded into a mailer position; and

[0013]FIG. 5 is a perspective view of the folded mailer of FIG. 4 illustrating a sticker or mailing seal being applied to hold the flaps together.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION

[0014] A mailer sheet construction of the present invention is illustrated generally at 100 in FIG. 1 and having top and bottom edges and left and right side edges. The sheet is preferably an 8½by eleven inch sheet, a standard size sheet for easy feed and printing in today's printers or copiers. The sheet can have a thickness of 9.5 mils and ink jet optimized coatings on both sides. The sheet is seen to include on its inside surface four (cut) score lines 108, 112, 116, 120 forming a centrally disposed rectangle, four perforated lines 124, 128, 132, 136 extending vertically outward from each of the corners of the rectangle to top or bottom edges of the sheet, and four inwardly angling substantially horizontal perforated lines 140, 144, 148, 152 extending out from each of the corners towards either the right or left side edges of the sheet. This pattern of score and perforated lines forms a top flap 160, a central panel 164, a bottom flap 168, four tear-away corner strips 172, 176, 180, 184, and left and right side flaps 188, 192.

[0015] The substantially horizontal perforated lines 140, 144, 148, 152 are preferably one-quarter inch of microperfs followed by an optional one-eighth inch cut, then repeats. The vertical perforated lines 124, 128, 132, 136 are preferably half inch of microperfs, followed by an optional one-eighth inch cut, then repeats. An example perforated line uses a 0.020 inch cut and a 0.007 inch tie. Preferred dimensions as indicated by the following reference numerals are: 196(a) (three inches), 196(b) (five inches), 196(c) (three inches), 196(d) (6.5 inches), 196(e) (one inch) and 196(f) (one inch).

[0016] The score lines can be cut or crushed score lines. A crushed score line does not actually fracture or cut the plane of the cardstock material so that when it is folded over and that edge is exposed to the mail stream there is not the possibility of it catching a piece of the paper and delaminating it. The crushed score lines can be formed using a single crush die on the inside of the sheet and a flat die on the opposite side. Other types of weakened separation or fold lines can be used as would be apparent to those skilled in the art. Two different die stations can be used to form the sheet construction, wherein one die includes all of the horizontal perforations and scores and the other has all of the vertical ones. It typically does not make any difference which station is first.

[0017] The user enters using appropriate software of his computer (not shown) the indicia to be printed on the inside and/or outside surfaces of one or more of the top flap 160, central panel 164 and bottom flap 168. (FIGS. 2-5 show the printed indicia.) Typically, the indicia includes the sender's and intended recipient's addresses 200, 204 on the outside of the central panel 164, and a message 208 (such as an advertisement) on the inside of the central panel 164 and maybe on the inside and/or outside of the top and/or bottom panels. The addresses can be entered into the software from another address file in the user's computer.

[0018] The user then feeds the sheet constructions 100 individually or automatically from a stack 212 in an infeed tray 216 of a printer 220 into the printer. An example of a printer or copier 220 having an infeed tray and an outfeed tray 224 is shown in FIG. 2, and a preferred printer is a desk top ink jet printer. The stack 212 of sheet constructions 100 is shown in the infeed tray 216, and a stack of sheet constructions 228 with the desired indicia printed thereon is shown in the outfeed tray 224.

[0019] The printed sheet 100 is removed from the outfeed tray 224 and the four corner tear off strips 172, 176, 180, 184 torn off, which forms the left and right side flaps 188, 192. The one or more substantially flat objects 240, 244 to be mailed are placed on the inside surface of the central panel 164, and the left and right side flaps 188, 192 are folded in, as shown by the arrows 250, 252 in FIG. 3. The bottom flap 168 is then folded up (or in) as shown by the arrow 254 in FIG. 4, and the top flap 160 is folded down (or in) as shown by the arrow 258 in FIG. 4. Thereby the left, right, top and bottom flaps 188, 192, 160, 168 enclose the article pocket whose floor is defined by the central panel 164. The top flap 160 is releasably secured to the bottom flap 168 by the user 262 using an adhesive sticker or mailing seal 270 having a perforation line as illustrated in FIG. 5. Other types of adhering means can be used such as adhesive or gum strips. The top and bottom flap folding orientation can be reversed, if desired.

[0020] Postage, if not already applied, can be applied to the outside surface of the central panel in the corner above the intended recipient's address. And the mailer 274 with its flat contents 240, 244 mailed. Even with a postcard insert, only standard and not extra postage is needed with a preferred embodiment of this invention.

[0021] The postcards 240, 244 can be the 8386 INK JET PRINT-TO-THE-EDGE POSTCARDS available in a two-up format from Avery Dennison Corporation of Pasadena, Calif. The product can be sold with twenty mailer sheets in a box with twenty sheets of these postcards.

[0022] From the foregoing detailed description, it will be evident that there are a number of changes, adaptations and modifications of the present invention which come within the province of those skilled in the art. For example, different dimensions and/or patterns of the weakened lines can be provided. The scope of the invention includes any combination of the elements from the different species or embodiments disclosed herein. However, it is intended that all such variations not departing from the spirit of the invention be considered as within the scope thereof. 

We claim:
 1. A sheet mailer construction, comprising: a sheet having top, bottom, left and right side edges; the sheet having left, right, top and bottom score lines forming a rectangle generally centrally disposed on a first face of the sheet, the left and right score lines being positioned parallel to one another and to the left and right side edges, and the top and bottom score lines being parallel to each other and to the top and bottom edges, the rectangle having upper right and left corners and lower right and left corners; the sheet having a first weakened line extending from the upper left corner to the top edge and parallel to left side edge, a second weakened line extending from the lower left corner to the bottom edge and parallel to the left side edge, a third weakened line extending from the upper right corner to the top edge and parallel to the right side edge, and a fourth weakened line extending from the lower right corner to the bottom edge and parallel to the right side edge; the sheet having a flap weakened first line extending from the upper left corner to the left side edge, a flap weakened second line extending from the lower left corner to the left side edge, that first and second lines forming a left side flap at the left score line; the sheet having a flap weakened third line extending from the upper right corner to the right side edge, and a flap weakened fourth line extending from the lower right corner to the right side edge, the third and fourth lines forming a right side flap at the right score line; the flap weakened first line and the first weakened line defining an upper left corner tear away strip; the flap weakened second line and the second weakened line defining a lower left corner tear away strip; the flap weakened third line and the third weakened line defining an upper right corner tear away strip; the flap weakened fourth line and the fourth weakened line defining a lower left corner tear away strip; the top score line, the flap weakened first line and the third weakened line defining a top flap; the rectangle forming a central panel; the bottom score line, the flap weakened second line and the fourth weakened line defining a bottom flap; the top flap, the bottom flap and the central panel all having the same width; the top flap and the bottom flap both having heights no greater than the height of the central panel; the sheet being adapted to be passed through a printer and in at least one printing operation address indicia printed on an outside surface of the central panel; after the at least one printing operation, the upper left, lower left, upper right and lower right corner tear away strips being adapted to be torn off whereby the sheet defines a mailer sheet; an inside surface of the central panel defining a floor of a pocket of the mailer sheet for mailing at least one substantially flat article; and with that at least one substantially flat article being on the floor, the left and right side flaps being folded towards the at least one substantially flat article, and one of the top or bottom flaps being folded towards the folded left and right side flaps and the other of the top or bottom flaps being folded down on the one of the folded top or bottom flaps and adhered to the other to enclose the at least one substantially flat article.
 2. The construction of claim 2 wherein in the printing operation, indicia is printed on at least one of the inside or outside surfaces of the top flap, the central panel and the bottom flap.
 3. The construction of claim 1 wherein the other of the top or bottom flaps has a height less than that of the one of the top or bottom flaps.
 4. The construction of claim 1 wherein the at least one substantially flat article comprises a postcard.
 5. The construction of claim 1 wherein the at least one substantially flat article comprises a plurality of postcards.
 6. The construction of claim 1 wherein the at least one substantially flat article comprises a compact disc.
 7. The construction of claim 1 wherein the score lines each comprise crushed score lines.
 8. The construction of claim 1 wherein the score lines each comprise cut score lines.
 9. The construction of claim 1 wherein the first, second, third and fourth weakened lines each comprise cut score lines.
 10. The construction of claim 1 further comprising a sticker for adhering the folded other of the top or bottom flaps to the folded one of the top or bottom flaps.
 11. The construction of claim 1 wherein the central panel has a width of 6½ inches and a height of five inches.
 12. The construction of claim 1 wherein the sheet is an 8½ by 11 inch paper sheet.
 13. The construction of claim 1 wherein the printer is a desk top ink jet printer.
 14. The construction of claim 1 wherein the flap weakened first and second lines angle towards one another, and the flap weakened third and fourth lines angle towards one another.
 15. The construction of claim 1 wherein the sheet is a paper sheet with ink jet optimized coatings on both sides.
 16. The construction of claim 1 wherein the sheet has a thickness of 9.5 mils.
 17. The construction of claim 1 wherein the top and bottom flaps are adhered with a mailing seal.
 18. A sheet mailer construction, comprising: a sheet having a pattern of weakened lines defining a support panel and extending out from edges of that panel top and bottom flaps and left and right side panels; the sheet after a printing operation thereon, including the top and bottom flaps and side panels being foldable to enclose at least one flat object on the support panel.
 19. A method of forming a mailer, comprising: (a) providing a sheet mailer construction which includes: a sheet having top, bottom, left and right side edges; the sheet having left, right, top and bottom score lines forming a rectangle generally centrally disposed on a first face of the sheet, the left and right score lines being positioned parallel to one another and to the left and right side edges, and the top and bottom score lines being parallel to each other and to the top and bottom edges, the rectangle having upper right and left corners and lower right and left corners; the sheet having a first weakened line extending from the upper left corner to the top edge and parallel to left side edge, a second weakened line extending from the lower left corner to the bottom edge and parallel to the left side edge, a third weakened line extending from the upper right corner to the top edge and parallel to the right side edge, and a fourth weakened line extending from the lower right corner to the bottom edge and parallel to the right side edge; the sheet having a flap weakened first line extending from the upper left corner to the left side edge, a flap weakened second line extending from the lower left corner to the left side edge, that first and second lines forming a left side flap at the left score line; the sheet having a flap weakened third line extending from the upper right corner to the right side edge, and a flap weakened fourth line extending from the lower right corner to the right side edge, the third and fourth lines forming a right side flap at the right score line; the flap weakened first line and the first weakened line defining an upper left corner tear away strip; the flap weakened second line and the second weakened line defining a lower left corner tear away strip; the flap weakened third line and the third weakened line defining an upper right corner tear away strip; the flap weakened fourth line and the fourth weakened line defining a lower left corner tear away strip; the top score line, the flap weakened first line and the third weakened line defining a top flap; the rectangle forming a central panel; the bottom score line, the flap weakened second line and the fourth weakened line defining a bottom flap; the top flap, the bottom flap and the central panel all having the same width; the top flap and the bottom flap both having heights no greater than the height of the central panel; and an inside surface of the central panel defining a floor of a pocket of the mailer sheet for mailing at least one substantially flat article; (b) passing through a printer and in at least one printing operation printing address indicia on an outside surface of the central panel; (c) after the at least one printing operation, tearing away the upper left, lower left, upper right and lower right corner tear away strips from the sheet whereby the sheet defines a mailer sheet; (d) with that at least one substantially flat article positioned on the floor, folding the left and right side flaps towards the at least one substantially flat article; (e) folding one of the top or bottom flaps towards the folded left and right side flaps and the other of the top or bottom flaps down on the one of the folded top or bottom flaps; and (f) adhering the folded other of the top or bottom flaps to the folded one of the top or bottom flaps to enclose the at least one substantially flat article in the mailer.
 20. The method of claim 19 wherein the printing includes printing indicia on at least one of inside surfaces of the top flap, the central panel and the bottom flap.
 21. The method of claim 19 wherein the adhering includes positioning a mailing seal across an edge of the other of the top or bottom flaps onto the folded one of the top or bottom flaps.
 22. The method of claim 19 wherein the printing operation includes printing on inside surfaces of all of the top flap, central panel and bottom flap.
 23. The method of claim 19 wherein the passing includes passing the sheet through the printer one time to print indicia on the inside surface and another time to print the address indicia on the outside surface.
 24. The method of claim 19 wherein the passing includes the printer being a duplexing printer.
 25. The method of claim 19 wherein the printer is a desktop ink jet printer.
 26. A mailer system, comprising: (a) a rectangular sheet having a pattern of weakened lines formed thereon, the lines form four corner tear-away strips, a central panel, left and right side flaps extending out from sides of the central panel, and top and bottom flaps extending out from top and bottom edges, respectively, of the central panel; the sheet is adapted to be passed through a printer and in a printing operation desired address indicia printed on an outside surface of the central panel; and the sheet is adapted after the printing operation to have the four corner tear-away strips torn away to convert the sheet into a mailer sheet; (b) at least one substantially flat object positionable on the inside surface of the central panel of the mailer sheet; and the side panels are adapted to be folded in towards the at least one substantially flat object and the top and bottom panels folded in to a folded position towards the folded side panels such that the mailer sheet comprises a folded mailer sheet; and (c) a seal for holding the folded top and bottom panels together such that the folded mailer sheet comprises a mailer enclosing the at least one substantially flat object for mailing.
 27. The system of claim 26 wherein the sheet is an 8½ by 11 inch paper sheet.
 28. The system of claim 26 wherein the printing operation includes indicia being printed on at least one of inside and outside surfaces of at least one of the top flap, central panel and bottom flap.
 29. The system of claim 26 wherein the printer is a desk top ink jet printer.
 30. The system of claim 26 wherein the at least one substantially flat article comprises a postcard. 